Process for fermented cereal beverages



Patentecl Sept. 14, 1943 UNITED STATES. PATENT ElC- PROCESS FOR FERMENTED CEREAL BEVERAGES Harry G. Atwood, Peoria, I1].

l'his invention relates to a process for producing a cereal wort or fermented beverage which is enzymically active, from a raw cereal such as corn, with only a small amount of malted grain, the proportions being approximately 80% of raw cereal and 20% of malted grain. The process permits rapid and economical filtration to provide a low cost cereal extract which may be concentrated to a syrup or fermented with yeast in a closed system for a short period of time with- No Drawing. Application December 6, 1940, Serial No. 368,853

i 4 Claims. (Cl. 9942) zymically active wort or 'beer from at least 65% or more of malt, the balance raw'or cooked cereals and syrups in an attempt to produce by.

temperature control during conversion a large amount of unfermenta-ble carbohydrates such as dextrins to act as a body material, and to lend foam holding properties which in reality were onlypartially accomplished and actually resultout filtration, then aseptically filtered and packaged without'pasteurizing to produce an enzymically active, biologically stable, chill-proofv beverage containing traces of carbohydrates and substantial amounts of soluble nitrogenous bodies. 7

ed'in a satiating sweetness in the finished prod-v uct detracting from its consumption. Furthermore, the-conventional brewing procedures did not teach the necessary action of the-enzymes as catalysts in the hydrolysis of complex compounds to simpler products which are soluble and bear The conventional process for obtaining extract a from cereals such as employed in the brewing industry produces a non-enzymically active wort or beer from cereals of which 65% is malted grain and the balance raw or cooked cereals or syrups processed by temperature control during conversion to produce a large amount of unfermentable carbohydrates such as'dextrins to actas body materials and to produce foam holding properties. The high proportion ,of malted grains used was dictated by the necessity of providing material to build up a thick filter bed to properly filter this'mixture; and because the raw grains produced colloidal viscoid properties which made effective, economical filtering practically impossible.

The particular object of this invention is to provide a process for producing a bacteria-free cereal extract from a large proportion of raw cereal and a low proportion of malted cereal which can be rapidly, effectively and economically filtered to produce a low cost enzymically active sterile wort which, when fermented with pure culture yeast for a short period of timewithout refrigeration, will contain only traces of carbohydrates and large amounts of soluble products which, after aseptic filtration will result in a biologically stable, clear, brilliant, chill-proof cereal was mainly'concerned. withproducing a non-enan important relationship to the filtration of the mash.

The object of my process is to teach and disclose an entirely new concept of'conversion' and a continuous bacterial free fermentation which permits the use of a minimum-amount i20%) of high Lintner malt, the balance being comprisedof a cheap source ofstarch converted into theoretical yields of extracts and effecting a rapid economical separation of the same by any conventional filter. In the past excess amounts of malt were necessary for the purpose of supplying a filter bed for the separation of the extract and in contradistinction I teach that a low costvsource of starch such as corn grits without regard to its fibrous content or ability to build up a filter bed can be used in excess amounts with a minimum amount of malt also free of fibrous material to produce a vrapidly economically filterable extract. I teach that a cereal beverage made from grains relatively free of their fiber content produces a far superior quality in the finished product than that produced from the same materials and their own fiber content... .A'cco'rding to my process I-make no attempt to produce unfermentable carbohydrates such as dextrins, destroy or restrict the action of enzymes, or to refrigerate over lengthy fermentation or storage periods. I do teach that as much fermentable sugars be producedand fermented, and as much soluble s' produced as possiblel All of these factors result in an'enzymically active sterile wort at low cost which when fermented with pure culture yeast for a short period, of time without refrigeration will contain only traces of carbohydrates, largeamounts of soluble products, and'which will be biologically stableand chill proof after aseptic filtratiomthus A requiring no pasteurization. Analysis shows 0.26 gm. protein is present in cc. of the finished beer. This is approximately the same as a popular beer now on the market. i

Previous brewing attempts havebeen made to accomplish the desirable features which I set forth but all have failed to accomplish the primary object ofquicklyrand economically separating the extract obtained from large amounts of raw cereal grain and small amounts of malt. Contrary to the old procedure it is not necessary to produce dextrin which in the past was thought necessary to lend so-called palate fullness and foam holding properties to the finished product. These properties can be better fulfilled by producing desirable non-coagulable permanently soluble products such as albumoses, peptones, etc., all lending to the finished product a more desirable, pronounced grain and hop bouquet and a stable, chill proof fermented cereal beverage.

Heretofore the brewing industry has been severely handicapped, through lack of conversion and filtration knowledge, in producing a cereal beverage at the lowest possible cost, while retaining all the desirable characteristics of the old beverage- The features that differentiate my' process fromthe old is that I make no attempt to product slow filtering mixtures which require sparging with subsequent loss .of extract in the I- add a sterile solution of enzymes to raw andcooked grains for the purpose residue grains.

palatability and there is a difference which can be fully recognized by connoisseurs between beer which has been naturally impregnated and those which have been artificially impregnated with carbon dioxide gas. The difference is in the superior foam-holding qualities and the greater intimacy of association of the gas obtained by natural impregnation. The objectionable features of the natural charging was that this process was expensive not only due to the time, and room required, but also to elaborate and expensive refrigeration'. Moreover, an important defect in this process was the fact that fermenting may not completely subside at the desired time but continue to act after the product was packaged for consumption. One of the features of my invention relates to treatment of the fermenting product to effect the most efficient economical and desirable carbonation. This is accomplished by maintaining the product during fermentation undera psessure of -10 lbs. the excess carbon dioxide gas generated and vented into the atmosphere' in one step eliminating the second of modifying into simpler compounds such com- 1 plex groups as proteins, carbohydrates, and fibers through the useoftemperature control in successive pressure ric'ooking and conversion steps to effect mobile fluid mixtures which are easily filterable to provide an enzymicallya'ctive wort and a comparatively dry residue-menial cake (60% moisture.)y Furthermore, the aseptically ferhaving only traces of carbohydrates in the fin-I,

ished product as compared to theold ,conven tional non-.enzymically 1 active product, having.- large amounts of residual carbohydrates of sublied upon beech wood, chips, and other related products to promote clarification but as these products were a source-of danger, due to biologi-- cal contamination, this has been gradually abandoned. As the beer clarified very slowly and improperly, breweries in general had to rely upon elaborate and costly filtration which detracted from the quality of the finished product.

In my process the mixtures are effectively separated to produce a clear wort before fermentation and by a novel cooking and conversion oper- -at1'on provides a liquid which clarified quickly and completely and does not require the elaborate and costly filtration necessary in the old procedure.

In the art of brewing, as it has been practiced in the past, two general methods of impregnating the beer with carbon dioxide gas have been followed. The first, termed natural charging consisted of impregnating the gas into the beer with self generated gasfiafter main fermentation by adding a portion of freshly fermenting beer in a closed container. The second, termed artificial charging" consisted of mixing the carbon dioxide gas into the beer by mechanical means effected by carbonators. The purpose of carbonating beer is to improve its appearance and and. consequent enzymically active wort (31 with an apparent Bailing of 13.8.

steps used in theold procedure. Analysis shows .0518 gm. maltose per cc. remains in the finished beer. This is equivalent to 0.25% alcohol by volume, indicating a practically theoretical yield of alcohol has been obtained. A popular beer now on the market shows an analysis of about twice as much maltose and six times 'as much dextrin.

This invention comprises a conversion of prodiluctsinto soluble form for rapid filtration and subsequent fermentation procedure which may syrup manufacture, brewing,

b'e'applied to malt and food products. The relationship of my in- =vention to the present conventional process will be further disclosed in the following detailed procedure. 7 I prefer to use specified periods of time, degrees of temperatures, use of sterile en zymic malt residue and solution, number of pres sure cooks, kind and weights of materials specified al hough I appreciate that various modifica tions may be desirable under variable conditions.

Pnocanmu: I

All cereals ground-100% to pass through a mesh screen.

2,000 gallon capacity malt tank Ground high Lintner value malt pounds 1,089 Water containing 1-800 parts U. S. P.

formaldehyde gallons 1,200

Malt flour free of husks mixed in water containing 1-800 parts formaldehyde is agitated 30 minutes and settled 30 minutes, after which the liquid diastase is' decanted and reserved. 1

8, 000 gallon capacity pressure cooker equipped with agitator Water gallons 2,300 Ground corn grits ;pounds 4,357 Finely shreddedhops do 225 This will produce approximately 97 barrels of gallons to barrel) The finely ground corn grits previously separated, finely ground sterile malt residue previouslyprepared is added to the water and held at 122 F. for minutes, the temperature gradually mately 45 minutes for primary conversion, after a which it is gradually heated to 160 idly filtered.

Amounts of materials necessary to produce one barrel of beer (31 gallons) F. and rap- P unds Old pro- Per cent Pounds New pro- Pounds cedure extract extract oedure extract Malt 37. 73. 09 26. 895 9. 90 7. 239 Corn 7. 28 87. 36 6. 359 39. M 31. W Rice 3. 92 92. 88 3. 640 Sugar and syrups 3.22 95.60 3.078 Hops 0. 68 0. 63

Old pro- Now procedure oedure pounds pounds extract extract Total pounds extract 30. 97 42. Weight of water in a barrel of beer 266. 56 266. Total weight of wort in barrel of beer. 306. 53 308. Bailing of wort 13.04 13.

In the foregoing description I have proposed to disclose an improved method of processing cereals for rapid filtration, increased fermentation efllciency, and preservation of vitamins which in all improve the overall efllciency and economy to produce a uniform distinctive type fermented cereal beverage of which the following are specific benefits obtained through the use of my new process: 7

An increased yield of cereal extractlves.

Quicker and more economical operations.

The use of low cost source of starch.

Elimination'of expensive and elaborate mash tun, brew kettle, and hop Jack.

Elimination of expensive and ation equipment.

A more uniform quality product in regard to palatability and bouquet. A distinctive and new type cereal; beverage. A chill proof beverage. A biologically stable require pasteurizing in order to be kept over long periods of time-without refrigeration. Bacterial free fermentation process.

A non-fattening beverage.

An enzymically active beverage.

Having thus disclosed my invention, 1 claim: 1. The method of processing raw grain in the manufacture of fennented stable, chill-proof and enzymically active cereal beverages which consists of the following steps; Preparing-a diastatically active sterile diastaste mixture'by mixing fine ground high-Lintner malt with approxi-- ,rnately nine times its weight of water and 50% U. S. P. formaldehydein the proportion of 800 water to one formaldehyde; agitating and settling the diastaste mixture and decanting thesterile elaborate refrigermalt grains from fifteen minutes, adding finely shredded hops in proportion of about 1 temperature to 180 F. and holding about fifteen minutes, then raising the. temperature to over 300 F. and cooling to about 122 F.; adding the decanted sterile diastase solution for primary conversion; heating to 160 F.; filtering the mixture in a rapid one-pass operation to produce a sterile wort and dry grain cake; and fermenting the wort under 5 to 10 lbs. per sq. in. pressure, thereby producing a stable, chill-proof, enzymically active cereal beverage.

2. The method of processing raw grains in the manufacture of fermented stable, chill-proof and enzymically active cereal beverage which consists of the following steps: Preparing a diastatically active sterile diastase mixture by mixing fine ground high-Lintner malt with water and 40% U. S. P. formaldehyde in the proportion of 800 water to one formaldehyde; agitating and settling the diastase mixture and decanting the sterile diastase solution; mixing four times as much fine ground corn as malt in water with the residue the diastase mixture; cooking the grain mixture by raising the temperature to about 122 F., gradually raising the temperature to 160 F., adding finely shredded hops in propor raising the temperature' to about 180 F., then raising the temperature to over 300 F. and cooling to about 122 F.; adding the decanted sterile diastase solution for primary conversion; heating to about 160 F.;

I sists of the following U. S. P. formaldehyde; agitating and settling beverage which does not diastase solution; mixing four times as much fine ground corn as malt in 'approximatelyfour and a half timesits weight in water with the residue malt grains fromthe diastase mixture to liquefy the mixture; cooking the grain mixture by raising the temperature to 122 F. and holding, gradu- F. and holding ally raising the temperature tol60 filtering themixture in a rapid one-pass operation to produce a sterile wort and dry grain cake; and fermenting the wort, thereby producing a stable, chili-proof enzymically active cereal beverage.

3. The method of processing raw grains in the manufacture of fermented stable, chill-proof and enzymically active cereal beverage which consteps: Preparing a diastatisterile diastase mixture by mixing high-Lintner malt withwater and cally. active fine ground the diastase mixture and diastase solution; mixing decanting the sterile fine ground corn in 1 water with the residue malt grains from the diastase mixture; cooking the grain mixture by raising the temperature to about F., adding finely shred-ded'hops, raising the temperatureto about F., then raising the temperature'to over 300 F. and cooling to about :122 F.; adding the decanted sterile diastase solution for primary conversion; heating to about 160 F.; filtering the mixture in a rapid one-pass operation to produce a sterile wortand dry grain cake; and fermenting i the wort, thereby'producing a stable, chill-proof enzymically active cereal beverage. 4

4. The method of processing raw grains in the V manufacture of fermented stable, chill-proof and enzymically active cereal beverage which consists of the following steps: Mixing fine ground corn with water; adding a diastatically active sterile diastase'solution to liquefythe mixture; cooking the mixture by raising the temperatureffirst to about 122"F., then raising to 160"- F. and adding finely shredded hops, then raising temperature to 180 F'., then over 300 F., then cooling to about 1 2 F.; adding sterilediastase solution for conversion, heating to about 160 F.; filtering .the mixture in a rapid one-pass operation to produce a sterile wort ;and fermenting thewort to produce a cereal beverage.

HARRY .G. ATWOOD.

to 20 of grain, raising the I I 

